Container and support frame system for bulk products

ABSTRACT

A container and supporting frame is provided for bulk storage of products intended to be scooped or scraped. A re-usable frame surrounds and supports a disposable container. The base of the frame includes a channel to support a lower lip of the container. An upper portion of the frame includes a contact surface, which may be a groove, for receiving a rim of the container. The frame supports the container against outward forces exerted by the user.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No. 62/556,683 filed on Sep. 11, 2017, the entire contents of which are incorporated herein by reference.

TECHNICAL FIELD

The present invention relates to the field of containers, particularly containers designed to hold bulk products that are intended to be scooped or scraped out of the container.

BACKGROUND

Paperboard containers are commonly used to package bulk products that are meant to be scooped or scraped out of the container, such as ice cream, sorbet, gelato, vegetable shortening, margarine, cookie dough, and the like. In use, such containers must resist substantial outward forces applied by the user, during the scooping or scraping action.

For wholesale quantities (e.g. 1 gallon or more), containers are often made from heavy gauge paperboard materials, with the top and bottom joined by steel rings. The use of heavy gauge paperboard and steel rings reinforces the container, to prevent structural failure during use. However, these features also add significant manufacturing expense, both in terms of material costs and assembly. In addition, the steel rings are not reusable and the combination of paperboard and metal makes such containers difficult to fully recycle.

SUMMARY OF THE INVENTION

The present invention combines a container with a re-usable frame. The frame provides added structural integrity to the container and may in some cases be reusable. In some embodiments, the container may also be of lightweight construction, so as to reduce manufacturing costs and waste. The container may be used to hold a variety of bulk materials, including bulk materials that are intended to be scooped or scraped out of the container, such as ice cream, sorbet, gelato, vegetable shortening, or cookie dough.

In one broad aspect, the invention provides a frame for receiving a container. The container has a bottom, at least one side, a lower lip joining the at least one side to the bottom, and a rim disposed along the side to define a container opening. The frame comprises a bottom support for contacting the bottom of the container, at least one side support for contacting the at least one side of the container, an upper portion of the at least one side support defining a frame opening for receiving the container, and a lower portion joining the at least one side support to the bottom support, wherein the container is detached from the frame.

In another broad aspect, the invention provides a frame for receiving a container. The container has a bottom, at least one side, a lower lip joining the at least one side to the bottom, and a rim disposed along the side to define a container opening. The frame has a bottom support for contacting the bottom of the container, at least one side support for contacting the at least one side of the container, an upper portion of the at least one side support defining a frame opening for receiving the container, and a lower portion joining the at least one side support to the bottom support, the lower portion defining a channel for receiving the lower lip of the container, the channel comprising an outer wall and an inner wall for receiving and supporting the lower lip of the container.

In another broad aspect, the invention provides a frame for receiving a container. The container has a bottom, at least one side, and a rim disposed along the side to define a container opening, and a groove between the rim and the at least one side. The frame has a bottom support for contacting the bottom of the container, at least one side support for contacting the at least one side of the container, a lower portion joining the at least one side support to the bottom support, and an upper portion of the at least one side support defining a frame opening for receiving the container, wherein the upper portion defines a contact surface for receiving and supporting the rim of the container, and the contact surface is a groove complementary to the rim of the container.

In preferred embodiments, the container is detached from the frame. In preferred embodiments, the frame has a lower lip joining the at least one side to the bottom, wherein the lower portion defines a channel for receiving the lower lip of the container, the channel comprising an outer wall and an inner wall for receiving and supporting the lower lip of the container. In preferred embodiments, the frame has a groove between the rim and the at least one side, wherein the upper portion defines a contact surface for receiving and supporting the rim of the container, and the contact surface comprises a ridge received by the groove of the container.

In an embodiment, the contact surface is a groove complementary to the rim of the container and/or the channel comprises an outer wall for contacting the lower lip of the container. The frame may be of skeletal or solid construction. In some embodiments, the bottom support has a hub and spoke arrangement. In some cases, the frame may be configured to nest with a frame of similar construction.

The container maybe removable from the frame after use. In some embodiments, the container and/or frame are frustoconical. The shape of the container and/or frame may also depend on the application, and includes cylindrical, triangular, rectangular, hexagonal, or octagonal prisms.

In another broad aspect, the invention provides a kit comprising a container as described above, in combination with a frame as described above.

In yet another broad aspect, the invention provides a method of disposing of a container. The container is as described above, and is situated in a frame as described above. The container is lifted from the frame and recycled or disposed of separately from the frame. The frame may then be re-used with a second container of similar construction.

BRIEF DESCRIPTION OF THE DRAWINGS

Advantages of the present disclosure will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

FIG. 1 is a perspective view of a frame and container according to an embodiment of the present invention.

FIG. 2 is a perspective view of a frame according to an embodiment of the present invention.

FIG. 3 is a bottom perspective view of a container according to an embodiment of the present invention.

FIG. 4 is a cross-sectional perspective view of the frame of FIG. 2, along plane A-A.

FIG. 5 is a side view of the frame of FIG. 2.

FIG. 6 is a front view of the frame of FIG. 2.

FIG. 7 is a top view of the frame of FIG. 2.

FIG. 8 is a bottom view of the frame of FIG. 2.

FIG. 9 is a perspective view of a container and a frame according to an embodiment of the present invention, in an assembled configuration.

FIG. 10 is a cross-sectional perspective view of the frame of FIG. 9, along plane B-B.

FIG. 11 is a front view of the cross-section shown in FIG. 10 normal to plane B-B.

FIGS. 12A and 12B are enlarged scrap views of the cross section shown in FIG. 11.

DETAILED DESCRIPTION

Referring to FIGS. 1-3, the invention generally comprises a frame 100 which receives a container 200. The frame 100 comprises a bottom support 110, at least one side support 130, a lower portion 120 joining the at least one side support 130 to the bottom support 110, and an upper portion 140 defining an opening in the frame for receiving the container 200. The container 200 likewise comprises a bottom 210, one or more sidewalls 230, a lower lip 220 joining the sidewalls 230 to the bottom 210, and a rim 240.

As seen in FIGS. 4 and 10-12, the lower portion 120 of the frame 100 defines a channel 122 for receiving the lower lip 220 of the container. In some embodiments, the outer wall of the channel 122 is in direct contact with the lower lip 220, which reinforces the junction between the bottom 210 and the sidewalls 230 of the container 200 when outward forces are applied.

In some embodiments, the upper portion 140 of the frame also defines a contact surface 142 for receiving the rim 240 of the container 200. In the embodiment shown in FIG. 12A, the contact surface 142 is a groove which is complementary to the rounded rim 240 of the container 200, which helps to prevent the opening of the container 200 from enlarging or collapsing during use. While the rim 240 shown in the Figures is a rounded convex, and the contact surface 142 shown in the Figures is a rounded concave, other shapes may be used, so long as the contact surface 142 secures and supports the rim 240. For example, triangular, rectangular, square or oval cross sections.

As best seen in FIGS. 12A and 12B, the contact surface 142 and the channel 122 seat the container 200 in the frame 100 and may reduce, or in some applications eliminate, the need for steel rings to be included in the container 200. A groove 244 may be located between the rim and the at least one side, and the upper portion 140 defines a contact surface 142 for receiving and supporting the rim 240 of the container, and the contact surface comprises a ridge 144 received by the groove 244 of the container.

The elimination of metal rings is beneficial, as metal detection of food products is an ever increasing and desirable practice in the industry. Food products inside packaging having metal rings cannot easily be scanned for errant and dangerous metal objects.

As seen in FIG. 11, the bottom support 110 and side support 130 of the frame 100 also reinforce the bottom 210 and sidewalls 230 of the container 200 against outward forces applied during scooping. In some applications, this may reduce the thickness of paperboard or other material required to form the container 200.

In the embodiment shown in FIG. 4, the bottom support 110 and sides 130 of the frame 100 have a skeletal arrangement, to minimize material usage and to facilitate removal of the container 200 from the frame 100. In this embodiment, the bottom support 110 comprises a hub 112 and a plurality of spokes 114, whereas the sides 130 are formed from an arrangement of vertical 130 and horizontal 132 members. Various other configurations are also contemplated, including non-skeletal arrangements.

In the figures, the container 200 has a frusto-conical shape, which reflects the most common format currently used in the industry. The frustoconical shape allows for nesting of multiple containers 200 and frames 100, either separately or combined, when they are empty.

However, numerous other configurations are possible. For example, cylindrical, square, hexagonal, octagonal, and various other arrangements of the container 200 are also contemplated. Likewise, the frame 100 may be of the same overall shape as the container 200, as shown in FIG. 9, or may be of various other shapes or configurations as appropriate for the application, so long as the container 200 is received within and supported by the frame 100. In some embodiments, the frame 100 and/or container 200 are designed to nest for storage.

In use, the container 200 is inserted into the frame 100 as shown in FIG. 9. The paperboard container 200 is received in the frame 100, but the paperboard container is not integrated with the frame 100.

The container may be placed in the basket (frame) before the container is filled. Thus a thinner, more economical paper container may be used, as the basket provides support going through the production line and freezing operation so the basket protects the container and its contents, such as ice cream.

Once frozen the package is sturdy enough to withstand the transportation process. The container can then be removed and reused in the filling and freezing process for further containers. It can however be shipped with the basket if desired and then returned once the container is emptied. Thus the baskets can remain at the filling plant, or be transported with the product.

After transport, bulk materials such as ice cream and the like are then scooped or scraped out of the container, often with pressures being exerted by the user against the sidewalls 230 or bottom 210 of the container 200. The basket (frame) serves to withstand these pressures, allowing a thinner, more economical paper container to be used.

When the container 200 is empty, the container 200 is lifted from the frame 100. The container 200 and frame 100 may then be separately reused, recycled, or disposed of. In some embodiments, such as when the container 200 is made of paperboard and the frame 100 is made of plastic, this may enhance the recycling of raw materials, by separating the waste streams prior to processing.

When stored awaiting filling, or for reuse or recycling, the tapered walls and frustoconical shape allow for nesting of both the container and the basket. Storage is a significant issue. The current straight wall packages with steel rings used for ice cream take up a large amount of storage or, if shipped in flat, require equipment in the dairy to assemble the container and labor is required to complete the assembly.

In some embodiments, the frame 100 is reusable. In some applications, the customer may retain an inventory of frames 100, which are used to house new containers 100 as they are received from the supplier. Alternatively, each container 200 could be shipped with a frame 100, as a kit, and the frame 100 may be returned by the customer to the supplier when the container 200 is empty. The latter approach could, for example, be encouraged through a deposit system.

The frame 100 and container 200 can be manufactured from various suitable materials, such as metals, plastics, paperboard, and the like. In a preferred embodiment, the frame 100 is manufactured by injection moulding from a freezer grade resin, such as HDPE or PP and/or the container is manufactured from a lightweight paperboard. Various other materials and manufacturing methods for the frame 100 and container 200 would be readily apparent to the person of skill in the art having regard to the present specification.

The invention has been described in an illustrative manner, and it is to be understood that the terminology, which has been used, is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced other than as specifically described. The subject matter described herein and in the recited claims intends to cover and embrace all suitable changes in technology. 

1. A frame for receiving a container, the container having a bottom, at least one side, and a rim disposed along the side to define a container opening, the frame comprising: a bottom support for contacting the bottom of the container; at least one side support for contacting the at least one side of the container; an upper portion of the at least one side support defining a frame opening for receiving the container; and a lower portion joining the at least one side support to the bottom support; wherein the container is detached from the frame.
 2. A frame for receiving a container, the container having a bottom, at least one side, a lower lip joining the at least one side to the bottom, and a rim disposed along the side to define a container opening, the frame comprising: a bottom support for contacting the bottom of the container; at least one side support for contacting the at least one side of the container; an upper portion of the at least one side support defining a frame opening for receiving the container; and a lower portion joining the at least one side support to the bottom support, the lower portion defining a channel for receiving the lower lip of the container, the channel comprising an outer wall and an inner wall for receiving and supporting the lower lip of the container.
 3. A frame for receiving a container, the container having a bottom, at least one side, and a rim disposed along the side to define a container opening, and a groove between the rim and the at least one side, the frame comprising: a bottom support for contacting the bottom of the container; at least one side support for contacting the at least one side of the container; a lower portion joining the at least one side support to the bottom support; and an upper portion of the at least one side support defining a frame opening for receiving the container, wherein the upper portion defines a contact surface for receiving and supporting the rim of the container, and the contact surface is a groove complementary to the rim of the container.
 4. The frame of claim 2, wherein the container is detached from the frame.
 5. The frame of claim 1, further comprising a lower lip joining the at least one side to the bottom, wherein the lower portion defines a channel for receiving the lower lip of the container, the channel comprising an outer wall and an inner wall for receiving and supporting the lower lip of the container.
 6. The frame of claim 2, further comprising a groove between the rim and the at least one side, wherein the upper portion defines a contact surface for receiving and supporting the rim of the container, and the contact surface comprises a ridge received by the groove of the container.
 7. The frame of claim 1, wherein the container is frustoconical.
 8. The frame of claim 7, wherein the frame is frustoconical.
 9. The frame of claim 1, wherein the container is a cylindrical, triangular, rectangular, hexagonal, or octagonal prism.
 10. The frame of claim 9, wherein the frame is a cylindrical, triangular, rectangular, hexagonal, or octagonal prism.
 11. The frame of claim 1, wherein the at least one side support is of skeletal construction.
 12. The frame of claim 1, wherein the bottom support comprises a hub and spoke arrangement.
 13. The frame of claim 1, wherein the frame is configured to nest with another frame of similar construction.
 14. The frame of claim 1, wherein the container contains ice cream, sorbet, gelato, vegetable shortening, or cookie dough.
 15. The frame of claim 1, wherein the frame is constructed from freezer grade resin.
 16. A kit comprising: a. a container having a bottom, at least one side, a lower lip joining the at least one side to the bottom, and a rim disposed along the side to define a container opening; and b. a frame according to claim
 1. 17. The kit of claim 16, wherein the container further comprises a lid.
 18. A method of filling a container having a bottom, at least one side, a lower lip joining the at least one side to the bottom, and a rim disposed along the side to define a container opening, the method comprising: a. placing the container into a frame according to claim 1; b. filling the container with a bulk product intended to be scooped or scraped out of the container.
 19. The method of claim 18, further comprising removing the frame for reuse.
 20. The method of claim 19, wherein the frame is removed prior to transporting the bulk product from a filling location to a use location.
 21. A method of disposing of a container having a bottom, at least one side, a lower lip joining the at least one side to the bottom, and a rim disposed along the side to define a container opening, the method comprising: a. lifting the container from a frame according to claim 1; b. disposing of or recycling the container; and c. re-using the frame with a second container of similar construction. 